Corner joint and method of manufacturing

ABSTRACT

Corner joints and methods of forming corner joints are described herein. The corner joints may provide the appearance of a mortise and tenon joint on both the exterior and interior surfaces of the corner joint, but include a mitered connection within the joint. Structures including at least one of the corner joints are also described.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation patent application of U.S.patent application Ser. No. 13/215,586 filed on Aug. 23, 2011, which ishereby incorporated by reference in its entirety.

BACKGROUND OF THE INVENTION

Corner joints and methods of forming such joints are described herein.

The structures used to join framing components in a variety ofstructures such as, e.g., window sashes, window frames, doors, doorframes, picture frames, etc. may take a variety of different forms. Insome instances, such as, e.g., windows or doors, corner joints may beformed by thermal welding of frame members at each corner. Examples ofsuch a method are described in, e.g., U.S. Pat. No. 5,603,585. In thecorner joints disclosed in that reference, the decorative appearance ofone side of the corner joint is improved because one of the frame memberincludes a flange that gives the finished joint the appearance of amortise and tenon joint structure because the visible joint between theframe members meeting at the corner joint is aligned along thelongitudinal axis of one of the frame members.

Although the use of thermal welding to form the corner joints in U.S.Pat. No. 5,603,585 produces joints that are structurally sound and, fromone side, have a visually pleasing appearance, thermally welded jointsare not without difficulties in the manufacturing process.

SUMMARY

Corner joints and methods of forming such joints are described herein.The corner joints preferably provide the external appearance of amortise and tenon joint on both the exterior and interior surfaces ofthe corner joint, but include a mitered connection within the joint. Themitered connection simplifies construction of the joint, while flangesthat surround at least a part of the mitered joint on both the interiorand exterior surfaces preferably provide a mortise and tenon appearanceto the finished corner joint.

In one aspect, corner joints as described herein may include, in someembodiments: a first frame member comprising a first corner end, whereinthe first corner end comprises a first mitered surface located betweenan inner squared flange and an outer squared flange; and a second framemember comprising a second corner end, wherein the second corner endcomprises a second mitered surface, an inner edge spaced inwardly fromthe second mitered surface, and an outer edge spaced inwardly from thesecond mitered surface, wherein the inner edge and the outer edge areoriented perpendicular to a longitudinal axis of the second framemember. The first mitered surface faces the second mitered surface, afree edge of the inner squared flange on the first frame member facesthe inner edge of the second frame member, and a free edge of the outersquared flange on the first frame member faces the outer edge of thesecond frame member.

In some embodiments of the corner joints described herein the firstframe member comprises a first corner end opening, wherein the secondframe member comprises a second corner end opening, and the corner jointfurther comprises a corner key comprising a first leg and a second leg,wherein the first leg is located in the first corner end opening and thesecond leg is located in the second corner end opening. In someembodiments, the corner joint comprises adhesive material locatedbetween the inner squared flange and the corner key and adhesivematerial located between the outer squared flange and the corner key.

In some embodiments of the corner joints described herein the cornerjoint comprises an adhesive injection port, wherein the adhesiveinjection port extends through a wall of the first frame member into aninterior volume of the first frame member and/or through a wall of thesecond frame member into an interior volume of the second frame member.In some embodiments, the adhesive injection port is aligned with anadhesive orifice formed through a corner key located within the cornerjoint, wherein adhesive material introduced through the adhesiveinjection port passes through the adhesive orifice before beingdistributed between the corner key and an interior surface of the framemember. In some embodiments, the corner key comprises a via connected tothe adhesive orifice by a channel formed in a first surface of thecorner key, wherein adhesive material passing through the adhesiveorifice flows into the channel and through the via to a second surfaceof the corner key. In some embodiments, the adhesive injection portextends through two walls of the frame member, and wherein the adhesiveinjection port is aligned with an adhesive orifice formed through acorner key located within the corner joint, wherein adhesive materialintroduced through the adhesive injection port passes through theadhesive orifice before being distributed between the corner key and aninterior surface of the frame member.

In some embodiments of the corner joints described herein an innersurface of the outer squared flange is adhesively attached to the secondframe member.

In some embodiments of the corner joints described herein an innersurface of the inner squared flange is adhesively attached to the secondframe member.

In some embodiments of the corner joints described herein an innersurface of the outer squared flange is adhesively attached to a cornerkey located within the corner joint, and the corner key comprises a dampositioned beneath the free edge of the outer squared flange such thatadhesive is not located between the free edge of the outer squaredflange and the corner key.

In another aspect, corner joints as described herein may include, insome embodiments, a first frame member comprising a first corner endthat comprises a first corner end opening, wherein the first corner endfurther comprises a first mitered surface located between an innersquared flange and an outer squared flange; a second frame membercomprising a second corner end that comprises a second corner endopening, wherein the second corner end further comprises a secondmitered surface, an inner edge spaced inwardly from the second miteredsurface, and an outer edge spaced inwardly from the second miteredsurface, wherein the inner edge and the outer edge are orientedperpendicular to a longitudinal axis of the second frame member; acorner key comprising a first leg and a second leg, wherein the firstleg is located in the first corner end opening and the second leg islocated in the second corner end opening; and adhesive material locatedbetween the inner squared flange and the corner key and adhesivematerial located between the outer squared flange and the corner key.The first mitered surface faces the second mitered surface, a free edgeof the inner squared flange on the first frame member faces the inneredge of the second frame member, and a free edge of the outer squaredflange on the first frame member faces the outer edge of the secondframe member.

In another aspect, methods of forming a corner joint as described hereinmay include, in some embodiments, forming a first mitered surface on afirst corner end of a first frame member, wherein the first miteredsurface is located between an inner squared flange and an outer squaredflange at the first corner end of the first frame member; forming asecond mitered surface on a second corner end of the second framemember; forming an inner edge spaced inwardly from the second miteredsurface and an outer edge spaced inwardly from the second miteredsurface, wherein the inner edge and the outer edge are orientedperpendicular to a longitudinal axis of the second frame member, andwherein the second mitered surface is located between the inner edge andthe outer edge; and attaching the first frame member to the second framemember such that the first mitered surface of the first frame member andthe second mitered surface of the second frame member face each otherwithin the corner joint, a free edge of the inner squared flange on thefirst frame member abuts the inner edge of the second frame member, anda free edge of the outer squared flange on the first frame member abutsthe outer edge of the second frame member.

In some embodiments of the methods of forming corner joints as describedherein, the method may include positioning a first leg of a corner keyin a first corner opening of a first corner end of a first frame memberand positioning a second leg of the corner key in a second corneropening of a second corner end of a second frame member. In someembodiments, the method further comprises providing adhesive materialbetween the inner squared flange and the corner key and between theouter squared flange and the corner key.

In some embodiments of the methods of forming corner joints as describedherein the method may further include injecting adhesive material intothe corner joint through an adhesive injection port extending through awall of the first frame member into an interior volume of the firstframe member and/or through a wall of the second frame member into aninterior volume of the second frame member. In some embodiments, theadhesive injection port is aligned with an adhesive orifice formedthrough a corner key located within the corner joint, wherein theadhesive material injected through the adhesive injection port passesthrough the adhesive orifice before being distributed between the cornerkey and an interior surface of the frame member. In some embodiments,the corner key comprises a via connected to the adhesive orifice by achannel formed in a first surface of the corner key, wherein theadhesive material injected through the adhesive orifice flows into thechannel and through the via to a second surface of the corner key.

In some embodiments of the methods of forming corner joints as describedherein using a corner key and an adhesive injection port, the adhesiveinjection port extends through two walls of the frame member, andwherein the adhesive injection port is aligned with an adhesive orificeformed through a corner key located within the corner joint, wherein theadhesive material injected through the adhesive orifice passes throughthe two walls of the frame member before being distributed between thecorner key and an interior surface of the frame member. In someembodiments, the adhesive material is injected through an injector thatis inserted through the two walls of the frame member until the injectoris in contact with the corner key at the adhesive orifice.

In some embodiments of the methods of forming corner joints as describedherein, an inner surface of the outer squared flange is adhesivelyattached to the second frame member.

In some embodiments of the methods of forming corner joints as describedherein, an inner surface of the inner squared flange is adhesivelyattached to the second frame member.

In some embodiments of the methods of forming corner joints as describedherein, an inner surface of the outer squared flange is adhesivelyattached to a corner key located within the corner joint, and whereinthe corner key comprises a dam positioned beneath the free edge of theouter squared flange such that adhesive material does not flow betweenthe free edge of the outer squared flange and the corner key.

In another aspect, a structure comprising a first frame member and asecond frame member attached to each other at a corner joint asdescribed herein may be provided. In such a structure, the corner jointmay include a first mitered surface located between an inner squaredflange and an outer squared flange on a first corner end of the firstframe member; and a second mitered surface located on a second cornerend of the second frame member, an inner edge spaced inwardly from thesecond mitered surface on the second corner end of the second framemember, and an outer edge spaced inwardly from the second miteredsurface on the second corner end of the second frame member, wherein theinner edge and the outer edge are oriented perpendicular to alongitudinal axis of the second frame member. In the corner joint, thefirst mitered surface faces the second mitered surface, a free edge ofthe inner squared flange on the first frame member faces the inner edgeof the second frame member, and a free edge of the outer squared flangeon the first frame member faces the outer edge of the second framemember.

In some embodiments of the structure described above, the structure maybe selected from the group consisting of a window sash, window frame,door, door frame, and picture frame.

The above summary is not intended to describe each embodiment or everyimplementation of the corner joints described herein. Rather, a morecomplete understanding of the invention will become apparent andappreciated by reference to the following Description of IllustrativeEmbodiments and claims in view of the accompanying figures of thedrawing.

BRIEF DESCRIPTION OF THE VIEWS OF THE DRAWING

FIG. 1 is an exploded perspective view of one embodiment of a cornerjoint as described herein.

FIG. 2 is an interior side view of the corner joint of FIG. 1 asassembled.

FIG. 3 is an exterior side view of the corner joint of FIG. 1 asassembled.

FIG. 4 is an interior side view of the first frame member used in thecorner joint depicted in FIGS. 1-3.

FIG. 5 is an exterior side view of the first frame member used in thecorner joint depicted in FIGS. 1-3.

FIG. 6 is an end view of the first frame member of the corner joint ofFIGS. 1-3 taken along the longitudinal axis defined by the first framemember.

FIG. 7 is an interior side view of the second frame member used in thecorner joint depicted in FIGS. 1-3.

FIG. 8 is an exterior side view of the second frame member used in thecorner joint depicted in FIGS. 1-3.

FIG. 9 is an end view of the second frame member of the corner joint ofFIGS. 1-3 taken along the longitudinal axis defined by the second framemember.

FIG. 10A is an interior side view of the corner joint of FIG. 1 asassembled depicting the location of adhesive within the corner joint.

FIG. 10B is a right side view of the corner joint of FIG. 10A depictingthe location of adhesive within the corner joint.

FIG. 10C is an exterior side view of the corner joint of FIG. 10Adepicting the location of adhesive within the corner joint.

FIG. 10D is a left side view of the corner joint of FIG. 10A depictingthe location of adhesive within the corner joint.

FIG. 10E is a top view of the corner joint of FIG. 10A depicting thelocation of adhesive within the corner joint.

FIG. 10F is a bottom view of the corner joint of FIG. 10A depicting thelocation of adhesive within the corner joint.

FIG. 11A is a an interior side view of one embodiment of a corner keyused in a corner joint as described herein.

FIG. 11B is a right side view of the corner key of FIG. 11A.

FIG. 11C is an exterior side view of the corner key of FIG. 11A.

FIG. 11D is a left side view of the corner key of FIG. 11A.

FIG. 11E is a top view of the corner key of FIG. 11A.

FIG. 11F is a bottom view of the corner key of FIG. 11A.

FIG. 12A is a view of one surface of a structure in the form of a windowsash that includes four corner joints as described herein.

FIG. 12B is a view of the opposite surface of the window sash of FIG.12A.

DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

In the following description of illustrative embodiments, reference ismade to the accompanying figures of the drawing which form a parthereof, and in which are shown, by way of illustration, specificembodiments. It is to be understood that other embodiments may beutilized and structural changes may be made without departing from thescope of the present invention.

Each of the corner joints described herein includes a pair of framemembers that meet at a corner in which the frame members are typically,but not necessarily arranged to form a right angle. Within the cornerjoint, both of the frame members preferably include a mitered surfacethat, in a corner joint formed at a right angle, is typically at a 45degree angle to the longitudinal axis of the frame member. Although thecorner joints described herein may be formed at right angles withmitered surfaces at a 45 degree angle, in some embodiments, the cornerjoints described herein may be used to connect frame members that do notmeet at a right angle and the angle of the mitered surfaces relative tothe longitudinal axes of the frame members may be adjusted accordingly(although it may be preferred that, in some embodiments, the miteredsurfaces bisect the angle formed by the frame members).

In the corner joints described herein, one of the frame memberspreferably includes an inner flange and an outer flange, with themitered surfaces being located between and at least partially obscuredby the flanges on both the interior and the exterior surfaces of thecorner joint. It may be preferred that at least one of the flanges belarge enough to completely obscure the mitered surfaces on at least oneof the exterior and interior surfaces of the corner joint.

The frame members attached at the corner joints described herein may befastened together by any suitable technique or combination oftechniques. Examples of some potentially suitable techniques may includethreaded fasteners (e.g., screws, etc.), pins, rivets, adhesives,welding (thermal and/or chemical), etc. It may be preferred that,regardless of the fastening technique or techniques used, the appearanceof the mortise and tenon joint provided by the combination of miteredsurfaces located between the flanges be preserved on the visibleexterior and interior surfaces of the corner joints.

In some embodiments, the corner joints described herein may include acorner key that fits within the ends of each of the frame members toassist with fastening the frame members together. As described herein,the corner key may preferably be an internal corner key, i.e., a cornerkey that is not visible from the exterior of the finished corner joint.

One illustrative embodiment of a corner joint as described herein isdepicted in the exploded view of FIG. 1. As seen there, the cornerjoints 10 includes a first frame member 20, a second frame member 40 anda corner key 60 that fits within the ends of each of the first framemember 20 and the second frame member 40. FIGS. 2 and 3 depict thecorner joint 10 of FIG. 1 as assembled. As a result, the corner key 60is not visible in FIGS. 2 and 3 because it is located within the firstframe member 20 and second frame member 40.

In addition to providing structural support for the corner joint 10, thecorner key 60 may also include features designed to control the flow ofadhesive within the corner joint when the corner joint itself isassembled. It should, however, be understood that the corner key may, insome embodiments, be considered optional. In other words, the corner key60 may not be required in all corner joints as described herein.

The illustrative corner joint 10 depicted in FIGS. 1-3 is the cornerjoint of a window sash is in, e.g., a casement window. As discussedherein, however, the corner joint constructions described herein can beused in any structure in which two frame members are to be connected ata corner where the appearance of a mortise and tenon joint is desired,e.g., other window sashes, doors, window frames, door frames, pictureframes, etc. In the window sash corner joint 10 depicted in FIGS. 1-3,what is typically referred to as the interior surface of the cornerjoint is seen in FIG. 2, while the exterior surface of the corner jointis seen in FIG. 3. These descriptions are, however, provided only forreference purposes and the corner joints described herein may be used inan opposite manner, i.e., what may typically be considered an interiorsurface may be used as an exterior surface and vice versa.

The frame members used in the corner joints described herein may bemanufactured by a variety of processes. It may, however, be preferredthat the frame members be manufactured of an extruded material which mayinclude fibers and a polymer, pultruded materials, etc. Examples of somepotentially suitable constructions for frame members that may be used toconstruct corner joints as described herein may include those describedin, e.g., U.S. Pat. No. 5,585,155 (Heikkila et al.); U.S. Pat. No.6,106,944 (Heikkila et al.); U.S. Pat. No. 6,210,792 Seethamraju etal.); U.S. Pat. No. 6,260,251 (Guhl); U.S. Pat. No. 6,280,667 (Koenig etal.); U.S. Pat. No. 6,342,172 (Finley); etc.

Referring generally to FIGS. 1-3, the first frame member 20 includes afirst corner end that faces the upwardly facing leg 64 of the corner key60. The first corner end may include a first corner end opening intowhich the leg 64 of corner key 60 is inserted. The corner key endopening of the first frame member 20 is, in the depicted embodimentpreferably provided by the open or hollow primary volume 22 formedwithin first frame member 20. In addition to the primary volume 22formed within frame member 20, the frame member 20 also includes asecondary volume 28 which may be provided to improve structuralintegrity of the frame member in some constructions.

Although the end of the frame member 20 may preferably be hollow suchthat it forms an interior volume capable of receiving the leg 64 of thecorner key 60, it should be understood that remainder of the framemember 20 may or may not be hollow. For example, in some embodiments,one or both of the volumes 22 and 28 may be solid and/or may be filledone or more materials such as foam, etc.

The first frame member 20 also preferably includes a first miteredsurface 36 that is located between an inner squared flange 32 and theouter squared flange 34. The inner squared flange 32 preferably includesa free edge 33, while the outer squared flange 34 preferably includes afree edge 35. The first mitered surface 36 that is located between theinner squared flange 32 and the outer squared flange 34 is morecompletely illustrated and described in connection with FIGS. 4-6.

The first frame member 20 may also include features such as a channel 24sized to receive a glazing panel (not shown) or other structure (e.g., adoor panel, etc.). The use of structural members such as frame member 20to hold structures such as, e.g., glazing panels, is known and will notbe further described herein. Other features also depicted in connectionwith the first frame member 20 include channels 26 which are designed toreceive weatherstripping materials to provide improved sealing when, forexample, a window sash is closed within a frame.

Still another feature depicted in connection with the first frame member20 is an injection port 30 that preferably extends through a wall of theframe member that forms a portion of the secondary volume 28 and,although not shown in FIG. 1, that also extends through the interiorwall that forms secondary volume 28 such that the adhesive injectionport 30 extends into the primary volume 22 of the frame member 20.

Although illustrative embodiments of the corner joints as describedherein use the combination of a corner key and adhesive material tosecure the corner joints, in some embodiments, the corner key alone maybe used to secure the joint, while in other embodiments, the corner keymay be used with one or more other fastening techniques, e.g., threadedfasteners (e.g., screws, etc.), pins, rivets, welding (thermal,ultrasonic, vibratory, and/or chemical), etc. to secure the cornerjoint.

In those embodiments of the corner joints described herein that aredesigned to be further secured with adhesive material in addition to acorner key, it may be preferred that, as assembled, the corner key 60includes an adhesive orifice 70 that is aligned with the adhesiveinjection port 30 in the first frame member 20. The use of thesefeatures in connection with the injection of adhesives or othermaterials into the corner joint 10 to strengthen and secure the cornerjoint.

In some embodiments, the injection port 30 in an area of the framemember 20 where the injection port 30 extends through at least two wallsof the frame member in which it is located. In the depicted embodiment,for example, the injection port extends through the two walls formingthe secondary volume 28 within the first frame member 20.

Although the injection port 30 is provided in the first frame member 20,it should be understood that in other embodiments, the injection portcould be provided in the second frame member 40. Furthermore, althoughone injection port is provided, in some embodiments, two or moreinjection ports may be provided.

The second frame member 40 as depicted in FIGS. 1-3 includes a secondcorner end that faces the leg 62 of the corner key 60. The second cornerend of the second frame member 40 may also include a second corner endopening into which the leg 62 of the corner key 60 is inserted when thecorner joint 10 is assembled. The second end opening of the second framemember 40 is, in the depicted embodiment, preferably provided by theprimary volume 42 defining an interior volume formed within the secondframe member 40.

In addition to the primary volume 42 formed within second frame member40, the second frame member 40 also includes a secondary volume 48 whichmay be provided to improve structural integrity of the frame member insome constructions. Although the end of the second frame member 40 maypreferably be hollow such that forms an interior volume capable ofreceiving the leg 62 of the corner key 60, it should be understood thatthe remainder of the frame member 40 may or may not be hollow asdiscussed above in connection with the first frame member.

The second frame member 40 includes a second mitered surface 56 that islocated such that it faces the first mitered surface of the first framemember 20 when the first frame member 20 and the second frame member 40are arranged to form the corner joint 10. The second corner end of thesecond frame member 40 also preferably includes an inner edge 53 that isspaced inwardly from the end of the second frame member 40 and thatfaces the free edge 33 of the inner squared flange 32. When the cornerjoint 10 is assembled, the free edge 33 and the inner edge 53 preferablyform a joint that is aligned with the longitudinal axis 21 of the firstframe member 20. It is that joint formed by the free edge 33 and theinner edge 53 that give the corner joint 10 the appearance of a mortiseand tenon joint structure when viewed from the direction seen in FIG. 2.

The second frame member 40 also preferably includes a second corner andhaving an outer edge 55 that is spaced inwardly from the end of thesecond frame member 40 and that faces the free edge 35 of the outersquared flange 34 of the first frame member 20. When the corner joint 10is assembled, the free edge 35 and the outer edge 55 of the second framemember 40 preferably form a joint that is aligned with the longitudinalaxis 21 of the first frame member 20. It is that joint formed by thefree edge 35 and the outer edge 55 that give the corner joint 10 theappearance of a mortise and tenon joint structure as described hereinwhen viewed from the direction seen in FIG. 3.

The second frame member 40 also includes features such as a channel 44sized to receive a glazing panel (not shown) or other structure (e.g., adoor panel, etc.) as discussed above in connection with channel 24 inframe member 20. Other features also depicted in connection with thesecond frame member 40 include channels 46 which are designed to receiveweatherstripping materials provide improved sealing when, for example, awindow sash is closed.

Referring now to FIGS. 4-6, views of a portion of the first frame member20 are seen including a first (typically an interior) side view in FIG.4, an opposite (typically an exterior) side view in FIG. 5, and an endview in FIG. 6 (taken along the longitudinal axis 21 as seen in FIGS. 2and 3). Among the features seen in FIG. 4 are the inner squared flange32, the outer squared flange 34, and the first mitered surface 36. Alarge portion of the first mitered surface 36 is depicted by a brokenline in FIG. 5 because a substantial portion of the first miteredsurface 36 is hidden behind the squared outer flange 34 in that view. Asseen in FIGS. 4-6, the first mitered surface 36 is located between theinner squared flange 32 and the outer squared flange 34. The firstmitered surface 36 has been shaded in FIG. 6 to more accurately identifythose portions of this view that constitute a part of the first miteredsurface 36.

Among other features seen in FIGS. 4-6, are the free edge 33 of theinner squared flange 32 and the free edge 35 of the outer squared flange34. Also seen in FIG. 6, are features such as the primary volume 22formed within the frame member 20, as well as the secondary volume 28also formed within the first frame member 20. Further, weatherstripping27 is depicted in one of the channels 26 although any suchweatherstripping is optional (the weatherstripping 27 is also depictedin FIG. 2).

Referring now to FIGS. 7-9, views of a portion of the second framemember 40 are seen including a first (typically an interior) side viewin FIG. 7, a second (typically an exterior) side view in FIG. 8, and anend view in FIG. 9 (taken along the longitudinal axis 41 as seen inFIGS. 2 and 3). Among the features seen in FIG. 7 are the inner edge 53that is spaced inwardly from the second mitered surface 56. As describedherein, the inner edge 53 abuts the free edge 33 of the first framemember 20 when the inner squared flange 32 is positioned over a portionof the second frame member 40 in the corner joint 10 as assembled (see,e.g., FIG. 2).

Another feature seen in the view of FIG. 8 is the outer edge 55 that isspaced inwardly from the second mitered surface 56 on the depicted sideof second frame member 40. As described herein, the outer edge 55 abutsthe free edge 35 of the outer squared flange 34 when the outer squaredflange 34 is positioned over a portion of the second frame member 40 inthe corner joint 10 as assembled (see, e.g., FIG. 3).

The second mitered surface 56 on the second frame member 40 preferablyfaces the first mitered surface 36 when the first frame member 20 andthe second frame member 40 are assembled to form a corner joint as seenin, e.g., FIGS. 2-3. The second mitered surface 56 has been shaded inthe end view of FIG. 9 to more clearly indicate which surfaces of secondframe member 40 are mitered in the end view of FIG. 9.

Although the corner joints described herein include edges that meet in away that is designed to give the joint the appearance of a mortise andtenon structure, a mitered portion of the joint formed by the firstmitered surface 36 and the second mitered surface 56 can be seen in theassembled corner joint 10 as depicted in FIG. 2. That portion of themitered joint formed within the corner joint 10 is, however, nottypically visible unless the corner joint 10 is, e.g., part of a windowsash that has been opened. As a result, the injection port 30, which maybe sealed with a plug, sealant, etc. after adhesive has been injectedinto the corner joint 10 without disturbing the mortise and tenonappearance of the corner joint 10 as described herein.

Among other features seen in FIGS. 7-9 are the primary volume 42 formedwithin the first frame member 40, as well as the secondary volume 48also formed within the second frame member 40. Further, weatherstripping47 is depicted in one of the channels 46, although any suchweatherstripping is, of course, optional (the weatherstripping 47 isalso depicted in FIG. 2).

As described herein, the corner joints manufactured using a corner keyto connect first and second frame members may be further reinforced bythe addition of adhesive materials that may be injected into the cornerjoint. In the illustrative embodiment depicted in FIGS. 1-9, the firstframe member 20 includes an optional adhesive injection port 30 thatextends through the first frame member into the primary interior volume22 of the first frame member 20 as described herein. In otherembodiments, however, it should be understood that the adhesive materialmay be provided within the corner joints described herein prior to orduring assembly of the first and second frame member and associatedcorner key such that an injection port may or may not be requiredprovide any such adhesive material. In those embodiments in whichadhesive material is injected into the corner joint, it may beadvantageous to clamp or otherwise apply pressure to the frame membersto facilitate the proper distribution of adhesive material within thecorner joints and/or to reduce or eliminate any leakage of the adhesivematerial onto visible surfaces of the corner joints.

Regardless of how the adhesive material used within the corner jointsdescribed herein is delivered to the interior of the corner joint, itmay be preferred that the adhesive be located between the corner key 60and a sufficient amount (in both number and surface area) of the innersurfaces of the frame members so that a structurally sound corner jointcan be provided. In some embodiments, the adhesive may preferably belocated between the inner squared flange and the corner key as well asthe outer squared flange in the corner key so that flanges can besecurely attached to the remainder of the corner joint. In someembodiments, inner surfaces of the outer squared flange and the innersquared flange may be adhesively attached to the second frame member inaddition to the corner (in those embodiments that include a corner key)or to the second frame member alone in those embodiments that do notinclude a corner key.

The “adhesive materials” that can be used to strengthen the cornerjoints in combination with corner keys as described herein may include,but are not limited to, material such as hot melt adhesives(thermoplastic, thermoset, etc.), epoxies, silicones, thermoplasticpolymers, thermoset polymers, adhesive tapes, pressure sensitiveadhesives, pressure-activated adhesives, etc. In some embodiments, the“adhesive materials” may not be considered as “adhesive” in theconventional sense, but may, when located within the corner joint with acorner key, further strengthen the corner joint by, e.g., increasing thefrictional connection between the components in the joint, forming amechanically interlocking structure within the corner joint, etc.

FIGS. 10A-10F are views of an assembled corner joint 10 that includeshaded areas which correspond generally to areas in which adhesive maypreferably be located between a corner key and the frame members andfrom which the corner joint 10 is constructed. FIG. 10A depicts aninterior side view of the corner joint 10 as assembled with the adhesivelocated in area 90 a underneath the inner squared flange 33, as well asother portions of the first frame member 20 and the second frame member40 adjoining the inner squared flange 33. A second area 92 a of adhesivemay also preferably be located towards the outside corner of the cornerjoint 10 along the juncture of the first mitered surface 36 and thesecond mitered surface 56.

In the view depicted in FIG. 10B, an area 90 b of adhesive is locatedbetween the first outer squared flange 34 of the frame member 20 and thecorner key and a second area 92 b of adhesive is located between thesecond frame member 40 and the corner key. From this perspective, thecorner joint 10 includes a juncture between the free edge 35 of theouter squared flange 34 and the outer edge 55 of the second frame member40. To reduce the likelihood of leakage of adhesive material through theinterface between the free edge 35 and the outer edge 55, it may bedesirable to restrict or limit the flow of any adhesive to the areadirectly underneath the interface between the free edge 35 and outeredge 55. In some embodiments (as will be described herein), the cornerkey 60 may include a dam that is positioned beneath the free edge 35 ofthe outer squared flange 34 when the corner joint is assembled. The dammay occupy a zone between two adjacent adhesive areas 90 b and 92 b asdenoted by reference number 94 in FIG. 10B.

FIG. 10C is an exterior side view of the corner joint 10 taken from theright side of the corner joint 10 as depicted in FIG. 10B. As a result,only surfaces of the first frame member 20 are seen in FIG. 10C.Adhesive is located in two areas 90 c and 92 c between the first framemember 20 and the corner key located within the corner joint 10 whenviewed from this angle.

FIG. 10D is a left side view of the corner joint 10 taken from the leftside of the corner joint 10 as depicted in FIG. 10B. When viewed fromthis angle, an area 90 d of adhesive is primarily located between thefirst frame member 20 and the corner key 60 located within the cornerjoint 10 (with a portion of the corner key 60 being located within theinterior volume of the second frame member 40).

FIG. 10E is a top view of the corner joint 10 as seen in FIG. 10B. Whenviewed from this angle, an area 90 e of adhesive is located between thecorner key 60 and the second frame member 40 (with a portion of thecorner key 60 being located within the interior volume of the firstframe member 20).

FIG. 10F is a bottom view of the corner joint taken from the bottom ofthe view seen in FIG. 10B. As a result, only surfaces of the secondframe member 40 are seen in FIG. 10F. Adhesive is located in between thesecond frame member 40 and the corner key in two areas 90 f and 92 fwithin the corner joint when viewed from this angle.

Taken together, it can be seen from the views depicted in FIGS. 10A-10Fthat it may be desirable to distribute adhesive to a variety ofinterfaces between the corner key 60 and the frame members 20 and 40that make up corner joint 10. It should, however, be understood thatcorner joints as described herein, may or may not include adhesivedistributed along all of the surfaces depicted in connection with thisillustrative embodiment. In some embodiments, less adhesive may beneeded to provide a corner joint with sufficient structural integrityand, in other embodiments, less adhesive may be needed.

FIGS. 11A-11F are views of one embodiment of a corner key that may beused in the corner joints described herein. FIG. 11A is an interior sideview of the corner key 60 including legs 62 and 64 (see, e.g., theexploded view of FIG. 1). Among the features depicted in connection withthe corner key 60 are the adhesive orifice 70 which, as describedherein, preferably aligns with the adhesive injection port 30 in thefirst frame member 20.

The corner key 60 also includes an optional spacer element 66, as wellas standoff elements 67. The spacer element 66 may be provided to assistwith retention of the leg 64 of the corner key 60 in a frame member. Forexample, as leg 64 of corner key 60 is inserted into the hollow end of aframe member, the corner key 60 may preferably be (at least partially)retained within the frame member by friction forces generated betweenthe spacer element 66 and the interior of the frame member in which leg64 is located. In some embodiments, the spacer element 66 may also bealigned with the adhesive injection port 30 (where such an adhesiveinjection port is provided) to interact with the adhesive injection portto further assist retention of the corner key 60 within the framemember.

The standoff elements 67 may be provided in areas in which adhesive isdistributed between the key 60 and the frame members during themanufacturing process to ensure that a sufficient volume of adhesive isprovided between the corner key 60 and the portions of the frame memberinto which the corner key 60 is inserted to provide an acceptable bondbetween the corner key 60 and the frame member.

Other optional features of the illustrative embodiment of the corner key60 depicted in FIG. 11A include openings 63 that may preferably bealigned with hardware that may be attached to a window sash (or otherstructure) in which the corner key 60 is located. The openings 63 may bepositioned to receive a screw or other fastener used to attach hardwareto the structure in which the corner key 60 is located. Mechanicalattachment of the corner key 60 to such hardware may, in someembodiments, further strengthen a corner joint manufactured using thecorner key 60 and/or strengthen the connection between the hardware andthe frame member.

FIG. 11B is an exterior side view of the corner key 60 of FIG. 11A. Asseen in the view of FIG. 11B, the corner key 60 includes a leg 62 and aleg 64, as well as standoff elements 67 all of which are describedabove. In addition, the view of corner key 60 as seen in FIG. 11Billustrates the connection of adhesive orifice 70 with a variety ofdistribution features used to distribute adhesive material to thevarious surfaces of the corner key 60 so that a corner joint withsufficient structural integrity can be provided.

Among the adhesive distribution features seen in FIG. 11B are channels72 and 74 which are used to distribute adhesive passing through adhesiveorifice 70 to vias 71 and 73, respectively. In other words, as adhesiveis injected through the adhesive orifice 70 it may preferably flowthrough channels 72 and 74 to vias 71 and 73, where the adhesive may befurther distributed to other areas within the corner joint 10. Forexample, via 71 is also seen in FIG. 11A and is used to distributeadhesive to the area 90 d of adhesive between the corner key 60 andframe member 20 as seen in FIG. 10D. Via 73 is used to distributeadhesive to the area 90 e of adhesive between the corner key 60 andframe member 40 as depicted in FIG. 10E.

Other adhesive distribution features seen on the corner key 60 in theview of FIG. 11B include a channel 75 that leads to the outside corner76 of the corner key 60. As a result, adhesive traveling through channel75 may be distributed to lowermost area 92 c of adhesive between thecorner key 60 and frame member 20 as depicted in FIG. 10 C and to thearea 90 f of adhesive located on the right edge of the frame member 20as depicted in 10F (which correspond to the outside corner of the cornerjoint).

Yet another adhesive distribution feature depicted in the corner key 60in the view seen in FIG. 11B is a dam 79 that is preferably positionedbeneath the free edge 35 of the outer square flange 34 and thecorresponding outer edge 55 formed on the second frame member 40 asdescribed herein. The dam 79 preferably prevents or restricts adhesivefrom flowing beneath the interface between the free edge 35 and theouter edge 55. As a result, leakage of the adhesive through thatinterface may be reduced or, preferably, eliminated.

Referring to the view of corner key 60 as seen in FIG. 11C (which is atop view of the corner key 60 as seen in FIG. 11B), the corner key 60includes leg 62 and leg 64, along with standoff element 67. Also seen inthe view of FIG. 11C is a via 77 used to assist in the delivery ofadhesive to area 92 f of adhesive as depicted in FIG. 10F.

Referring to the view of corner key 60 as seen in FIG. 11D (which is abottom view of the corner key 60 as seen in FIG. 11B), the corner key 60includes leg 62 and leg 64, as well as via 77 through which adhesiveflows to the rectangular area surrounding via 77.

Referring to the view of corner key 60 as seen in FIG. 11E (which is aview taken from the right of the corner key 60 as seen in FIG. 11B), avia 78 is provided in the rectangular area that is associated with thearea 90 c of adhesive as seen in FIG. 10C. Also seen in the view of FIG.11E are standoff elements 67.

Referring to the view of corner key 60 as seen in FIG. 11F (which is aleft side view of the corner key 60 as seen in FIG. 11B), the via 78described above in connection with FIG. 11E is seen within the cornerkey 60 and it is through this via that adhesive is delivered to therectangular area depicted in FIG. 11E and in which via 78 is located.

The corner key 60 depicted and described in connection with FIGS.11A-11F is only one embodiment of a multitude of different embodimentsof corner keys that could be used to construct corner joints asdescribed herein. The specifics with respect to distribution of adhesivethroughout the various surfaces of the corner key may be varied asneeded depending on a variety of factors including the size of thecorner key and the frame members, the properties of the adhesive beingdelivered (e.g., the viscosity, tackiness, density, curing and/orhardening properties, and other characteristics of the adhesives). As aresult, it should be understood that many different embodiments ofcorner keys could be used to construct corner joints according to theprinciples described herein.

FIGS. 12A and 12B are provided to illustrate one example of structurethat could be constructed with the appearance of mortise and tenonjoints as described herein. In this depicted embodiment, the structure100 may be in the form of a window sash, although, as described above,the corner joints described herein may be used in any structure in whichtwo frame members are to be connected at a corner where the appearanceof a mortise and tenon joint is desired, e.g., doors, window frames,door frames, picture frames, etc. Any of these structures may be used inexterior and/or interior applications. Although the structure 100depicted in FIGS. 12A and 12B has a different appearance on its opposingsides, in some embodiments the structure may have the same appearance onboth sides. For example, in some embodiments, both sides of thestructure may have the appearance depicted in FIG. 12A, while in otherembodiments both sides of the structure may have the appearance depictedin FIG. 12B.

The sash 100 depicted in FIG. 12A includes a pair of vertical framemembers 104 and a pair of horizontal frame members 106. At each of thefour corners in the sash 100, a visible joint 102 is provided and isoriented along the longitudinal axis of one of the frame members toprovide the appearance of a mortise and tenon joint structure asdescribed herein. In many embodiments, the surfaces seen in the sash 100as depicted in FIG. 12A would be found on the exterior of a window sash,although it should be understood that these features could be reversedin certain situations (i.e., they could be found on an interiorsurface).

Referring to FIG. 12B, an opposing side or surface of the sash 100 seenin FIG. 12A which would typically correspond to the interior of a windowsash is depicted. As discussed herein, however, the sash 100 may be inthe form of a casement window sash that includes an inset edge 105 alongthe vertical frame members 104 and an inset edge 107 along thehorizontal frame members 106. The inset edges would typically not bevisible when the sash 100 is closed within a window frame in which thesash 100 is mounted.

Again, the frame members 104 and 106 are arranged and form corner jointseach of which include a visible joint 103 that is oriented along thelongitudinal axis of one of the frame members to provide the appearanceof a mortise and tenon joint structure as described herein. Further, asseen and described in connection with FIG. 2, portions of the sash 100as seen in FIG. 12B may include a mitered joint 108 that forms a 45°angle at the corner with both of the frame members 104 and 106. Thesemitered joints 108 are, however, preferably limited to the junctionsbetween the inset edges 105 and 107 and are, therefore, not typicallyvisible unless the window sash is open within its window frame. In otherwords, when the window sash is closed, only the joint structure 103corresponding to a mortise and tenon joint structure would typically bevisible.

The complete disclosure of any patents, patent documents, andpublications identified herein are incorporated by reference in theirentirety as if each were individually incorporated.

Illustrative embodiments of the corner joints and methods of making themare discussed and reference has been made to possible variations. Theseand other variations and modifications in the invention will be apparentto those skilled in the art without departing from the scope of theinvention, and it should be understood that this invention is notlimited to the illustrative embodiments set forth herein. Accordingly,the invention is to be limited only by the claims provided below andequivalents thereof.

What is claimed is:
 1. A corner joint comprising: a first frame memberdefining a longitudinal axis and comprising a first corner end, whereinthe first corner end comprises a first mitered surface located betweenan inner squared flange and an outer squared flange, wherein the innersquared flange defines a first surface on one side of the first miteredsurface and the outer squared flange defines a second surface on anopposite side of the first mitered surface substantially parallel to thefirst surface such that the first mitered surface is located between thefirst and second surfaces, wherein the inner squared flange comprises afree edge aligned with the longitudinal axis of the first frame memberand wherein the outer squared flange comprises a free edge aligned withthe longitudinal axis of the first frame member; and a second framemember defining a longitudinal axis and comprising a second corner end,wherein the second corner end comprises a second mitered surface, aninner edge spaced longitudinally inwardly from the second miteredsurface, and an outer edge spaced longitudinally inwardly from thesecond mitered surface, wherein the inner edge and outer edge extendtransversely to the longitudinal axis of the second frame member,wherein the free edge of the inner squared flange on the first framemember faces the inner edge of the second frame member to form an innerjoint aligned with the longitudinal axis of the first frame member, andwherein the free edge of the outer squared flange on the first framemember faces the outer edge of the second frame member to form an outerjoint aligned with the longitudinal axis of the first frame member;wherein the first mitered surface faces the second mitered surfacebetween the first surface of the inner squared flange and the secondsurface of the outer squared flange of the first frame member, whereinthe first mitered surface and the second mitered surface define a miterjoint plane that forms an acute angle with the longitudinal axis of thefirst frame member and an acute angle with the longitudinal axis of thesecond frame member.
 2. A corner joint according to claim 1, wherein thefirst frame member comprises a first corner end opening, wherein thesecond frame member comprises a second corner end opening, and whereinthe corner joint further comprises a corner key comprising a first legand a second leg, wherein the first leg is located in the first cornerend opening and the second leg is located in the second corner endopening.
 3. A corner joint according to claim 2, wherein the cornerjoint comprises adhesive material located between the first surface ofthe inner squared flange and the corner key and adhesive materiallocated between the second surface of the outer squared flange and thecorner key.
 4. A corner joint according to claim 1, wherein the cornerjoint comprises an adhesive injection port aligned with an adhesiveorifice formed through a corner key located within the corner joint,wherein adhesive material introduced into the corner joint through theadhesive injection port passes through the adhesive orifice before beingdistributed in the corner joint.
 5. A corner joint according to claim 4,wherein the corner key comprises a via connected to the adhesive orificeby a channel formed in a first surface of the corner key, whereinadhesive material passing through the adhesive orifice flows into thechannel and through the via to a second surface of the corner key.
 6. Acorner joint according to claim 1, wherein the corner joint comprisesadhesive material located between the first surface of the inner squaredflange and the second frame member, and wherein the corner joint furthercomprises adhesive material located between the second surface of theouter squared flange and the second frame member.
 7. A corner jointaccording to claim 6, wherein the corner joint further comprises amechanical fastener connecting the first frame member and the secondframe member.
 8. A corner joint according to claim 7, wherein theadhesive material comprises silicone.
 9. A corner joint according toclaim 1, wherein adhesive material is located between the second surfaceof the outer squared flange and a corner key located within the cornerjoint, and wherein the corner key comprises a dam positioned beneath thefree edge of the outer squared flange such that the adhesive material isnot located between the free edge of the outer squared flange and thecorner key.
 10. A method of forming a corner joint, the methodcomprising: forming a first mitered surface on a first corner end of afirst frame member, wherein the first mitered surface is located betweenan inner squared flange and an outer squared flange at the first cornerend of the first frame member, wherein the inner squared flange definesa first surface on one side of the first mitered surface and the outersquared flange defines a second surface on an opposite side of the firstframe member substantially parallel to the first surface such that thefirst mitered surface is located between the first and second surfaces,and wherein the inner squared flange comprises a free edge aligned witha longitudinal axis of the first frame member and the outer squaredflange comprises a free edge aligned with the longitudinal axis of thefirst frame member; forming a second mitered surface on a second cornerend of a second frame member; forming an inner edge on the second framemember that is spaced longitudinally inwardly from the second miteredsurface along a longitudinal axis of the second frame member, andforming an outer edge on the second frame member that is spacedlongitudinally inwardly from the second mitered surface, wherein theinner edge and outer edge extend transversely to the longitudinal axisof the second frame member; positioning the first frame member and thesecond frame member such that: the free edge of the inner squared flangeon the first frame member faces the inner edge of the second framemember to form an inner joint aligned with the longitudinal axis of thefirst frame member; the free edge of the outer squared flange on thefirst frame member faces the outer edge of the second frame member toform an outer joint aligned with the longitudinal axis of the firstframe member; and the first mitered surface faces the second miteredsurface between the first surface of the inner squared flange and thesecond surface of the outer squared flange of the first frame member,wherein the first mitered surface and the second mitered surface definea miter joint plane that forms an acute angle with the longitudinal axisof the first frame member and an acute angle with the longitudinal axisof the second frame member; and attaching the first frame member to thesecond frame member after positioning the first frame member and thesecond frame member such that the inner joint and the outer joint areformed.
 11. A method according to claim 10, further comprisingpositioning a first leg of a corner key in a first corner opening of afirst corner end of the first frame member and positioning a second legof the corner key in a second corner opening of a second corner end ofthe second frame member.
 12. A method according to claim 11, wherein themethod further comprises providing adhesive material between the firstsurface of the inner squared flange and the corner key and between thesecond surface of the outer squared flange and the corner key.
 13. Amethod according to claim 10, wherein the method further comprisesinjecting adhesive material into the corner joint through an adhesiveinjection port aligned with an adhesive orifice formed through a cornerkey located within the corner joint, wherein the adhesive materialinjected through the adhesive injection port passes through the adhesiveorifice before being distributed in the corner joint.
 14. A methodaccording to claim 13, wherein the corner key comprises a via connectedto the adhesive orifice by a channel formed in a first surface of thecorner key, wherein the adhesive material injected through the adhesiveorifice flows into the channel and through the via to a second surfaceof the corner key.
 15. A method according to claim 9, wherein the methodcomprises: providing adhesive material between the first surface of theinner squared flange and the second frame member; and providing adhesivematerial between the second surface of the outer squared flange and thesecond frame member.
 16. A method according to claim 14, wherein themethod comprises connecting the first frame member and the second framemember using a mechanical fastener.
 17. A method according to claim 15,wherein the adhesive material comprises silicone.
 18. A window or doorframe comprising a first frame member and a second frame member attachedto each other at a corner joint, wherein the corner joint comprises: afirst frame member defining a longitudinal axis and comprising a firstcorner end, wherein the first corner end comprises a first miteredsurface located between an inner squared flange and an outer squaredflange, wherein the inner squared flange defines a first surface on oneside of the first mitered surface and the outer squared flange defines asecond surface on an opposite side of the first mitered surfacesubstantially parallel to the first surface such that the first miteredsurface is located between the first and second surfaces, wherein theinner squared flange comprises a free edge aligned with the longitudinalaxis of the first frame member and wherein the outer squared flangecomprises a free edge aligned with the longitudinal axis of the firstframe member; and a second frame member defining a longitudinal axis andcomprising a second corner end, wherein the second corner end comprisesa second mitered surface, an inner edge spaced longitudinally inwardlyfrom the second mitered surface, and an outer edge spaced longitudinallyinwardly from the second mitered surface, wherein the inner edge andouter edge extend transversely to the longitudinal axis of the secondframe member, wherein the free edge of the inner squared flange on thefirst frame member faces the inner edge of the second frame member toform an inner joint aligned with the longitudinal axis of the firstframe member, and wherein the free edge of the outer squared flange onthe first frame member faces the outer edge of the second frame memberto form an outer joint aligned with the longitudinal axis of the firstframe member; wherein the first mitered surface faces the second miteredsurface between the first surface of the inner squared flange and thesecond surface of the outer squared flange of the first frame member,wherein the first mitered surface and the second mitered surface definea miter joint plane that forms an acute angle with the longitudinal axisof the first frame member and an acute angle with the longitudinal axisof the second frame member.
 19. A window or door frame according toclaim 18, wherein the first frame member comprises a first corner endopening, wherein the second frame member comprises a second corner endopening, and wherein the corner joint further comprises a corner keycomprising a first leg and a second leg, wherein the first leg islocated in the first corner end opening and the second leg is located inthe second corner end opening.
 20. A window or door frame according toclaim 18, wherein the corner joint comprises adhesive material locatedbetween the first surface of the inner squared flange and the corner keyand adhesive material located between the second surface of the outersquared flange and the corner key.
 21. A window or door frame accordingto claim 18, wherein the corner joint comprises an adhesive injectionport aligned with an adhesive orifice formed through a corner keylocated within the corner joint, wherein adhesive material introducedinto the corner joint through the adhesive injection port passes throughthe adhesive orifice before being distributed in the corner joint.
 22. Awindow or door frame according to claim 21, wherein the corner keycomprises a via connected to the adhesive orifice by a channel formed ina first surface of the corner key, wherein adhesive material passingthrough the adhesive orifice flows into the channel and through the viato a second surface of the corner key.
 23. A window or door frameaccording to claim 18, wherein the corner joint comprises adhesivematerial located between the first surface of the inner squared flangeand the second frame member, and wherein the corner joint furthercomprises adhesive material located between the second surface of theouter squared flange and the second frame member.
 24. A window or doorframe according to claim 23, wherein the corner joint further comprisesa mechanical fastener connecting the first frame member and the secondframe member.
 25. A window or door frame according to claim 24, whereinthe adhesive material comprises silicone.
 26. A window or door frameaccording to claim 18, wherein adhesive material is located between thesecond surface of the outer squared flange and a corner key locatedwithin the corner joint, and wherein the corner key comprises a dampositioned beneath the free edge of the outer squared flange such thatthe adhesive material is not located between the free edge of the outersquared flange and the corner key.